Pattern for rail welding molds



Jan. 24, 193,3.

B. RCNAY PATTERN FOR RAIL WELDING MOLDS Filed Aug. 5, 1932 5Sheets-Sheet 1 /N VENTO/e Hm A TTQRNE y Jan. 24, 1933. B. RONAY PATTERNFOR RAIL WELDING MoLDs Filed Aug. 5, 1952 3 Sheets-Sheet 2 /N VENTO/eHIS A TTORNE y Jan. 24, 1933. B. RoNAY PATTERN FOR RAIL WEILDING MOLDS 3Sheets-Sheet 3 Filed Aug. 5. 1932 HIJA TTORNEY Patented Jan. 24, 1933UNITED STATES TIoN, or CARTERET, NEW JERSEY, A eoRloRATIoN or NEW`JERsmzl PATTERN FOR RAIL wELDING'MoLDs Application led Augustr, 19372tlSerial Nc. 627,58.

i The invention relates to, patterns for rail welding molds and has forits object to provide said patterns in such form as to be adapt.

able in the construction or. formation of standard two part molds or ofspecial four part molds, thereby avoiding the necessityr of providingVseparate sets of patterns for these diiferent mold types as hasbeen'the practice heretofore.`V y c i 'The inventionis illustrated `inthe accompanying drawings, inwhich Fig. 1 is an end elevation of a setofpatterns applied in the construction of afour partV mold for weldinggirder or trilhyV rails, the mold parts being shown in section.

Y Fig.v 2 is a plan view of the pattern sets. y. Fig. 3V isV a frontelevation of theV pattern for the mold section or sections for thegroove or lip side of the rail. f Figs. 4l` and 5 are sectionalelevations yof four part molds for girder and T-rails, respecv tively..i i y f y V y v p In the art of welding rails by fusing the endsthereof together bymeans ofsuperheatedv molten metal, such as thermitsteelo'fr steel alV` a loys, the general practice Ihas been .to surroundand enclose the ends ofthe lrails in a refractory mold usually formed oftwo parts, so that the completed mold'fis dividedion va vertical planecoincident with the longitudinalv axes of therails. When these two partmolds are employed for welding T-,rails,'there isnol particularcomplication becausethe railsare symmetricalY about a vertical axis'andthe half molds are parted ,on the vertical plane aforesaid, but, inthe case of girder or trilbyvrails, no such symmetry exists andconsequently' that portion of the mold' which is Vdesignedito'fit intothe groove of the rail between the head andlipportion cannot be part ofthe corresponding 'half moldfbut must be formed either as a separatecorepiece orby packing refractory mold materialinto the groove beforethe application of the twoy halfmolds. f

In rail welding work under trailic, ithas been customaryto employ threepart molds, such as disclosed in thepatent to Deppeler No."1,813,032,comprising lower mold sections enclosing therail ends to substantiallythermic welding of frails, som'e operators the level ofthe tread surfaceofthe-rails, and anlupper or cope section fitted to and ,con-l stitutinga completing supplement. to" the lower. sections, so that the upper orcopesec 55d tion maybe :removed during the welding opv erations'to allowythe passage of'trafc overther site of the'joint.` With this three-partymold, the fcope portion necessarily includes the portion of therefractory materialwhich exten ds into the grooves of the rails and'thus eliminates the necessityof forming aseparate core for'the groovesectiony as hereinbefore stated. i f v In the commercial practice ofaluminoprefer the standard practice and avoid :any interference withtrafHc by discontinuing operations while trafeis, passing Onl the vother hand, others find it necessary. or prefer to dol all ,of theirwelding .with threeA part moldsv and withoutinterrupting traflic; whileothers, who do the bulk of their work with two part molds, therebyinterrupting, tralc, occasionally, desire todo'some workiwitho'utinterruption to tralc y and z are; therefore, obligedtoikeep on hand twosets of welding equipment forithesame railfc'ontours, including two setsof patterns, oneset forthe two partimold and anotherand separate set forthe three part mold. Toavoid/thefdiiii# culty and expense voff providingduplicate' pattern and mold 'box equipment, it has beenV f found that,by employing patternlfsets'fof'the character hereinafterdescribedand'bydivid-V ing each half mold box horizontally at about thelevel ofthe running surface of the rails, the necessary equipment. forperformingthe welding operations, under either'of theconditionsaforesaid relative to traffic, will require only one set of mold boxesand one set of patterns forforming either twopart `or four part'moldsections, and the dpresentv invention has to do with the specialconstrue# tion ofthe patterns to adapt the same to the construction ofeither two part or k.four-part `95 molds.` g N .y Y e Referringto thedrawings, which illustrate' the invention as applied to pattern sets forforming-molds employed Yin the welding of girder or trilby rails, 1:indicates .the back- 10oY PATE'NTPOFHCE EELA RoNAY, or ANNAPoLIs;MARYLAND, AssIeNoR To METAL sa THERMIT coRPoRA- 303 Formed on the frontface 1is a pattern section 10, which, for its larger part, conformsstrictly to one-half section ofV board as employed for the formation ofthe mold section for the groove or lip side of the rails, the rear faceof the backboard being provided withspaced guide members 2, 2,

5 fitted with angle irons 3, 3, between which guides is located a slide4 capable of movement in aplane parallel to the surface ofthe backboard,the slide being held in position by the angle irons 3, 3. Secured totheupper endk of the slide i'fisv a headboard 5, which,ji'n itsv variouspositions of operation, isnormal to the plane of the backboard 1. Asimilar construction and arrangement of' backboard,

headboard and slide is provid-ed for the coordinate pattern section uponwhich the mold sectionA for the head side of the rails kis formed, thesimilar parts being indicated by primed numerals 1-to 5 inclusive.Preferably, means are provided for locking the headboard to thebackboard, Yunder certainV Vconditions of use,the particular meansexemplified in the drawings consisting ofordinary hooks'and eyes 6 and6. It will be noted that` the backboards 1 and 1 are substantially co-95` extensive with the inner faces of thecorrespending mold sections anddefine kthe inner facesy ofsaid mold sections which abut each other whenthe mold is assembled about thek ends of the rails.V 1

of the backboard the rail to bewelded, the intermediateportion of thepattern element being. provided 35;.with a rib or extension 11, whichdefines the reinforcing collar to be formed inthe weldedv j oint.

5 isapattern section 12, which defines sub- @0f stantially one-half ofthe vslag-:basin or reaction chamber as lusually providedv inthe uporcope section of the mold, this pattern s per section'having extendingtherefrom thejp-at'-, tern section 13, which constitutes the pattern j45 for the pouring gate, which is usually located in the completed moldyimmediately above the gap separating, the rail. ends on the lip side.

Similarly securedtothe front face of theV backboard 1 is a patternsectionr10 fasl1. ioned to conform to the contour'of the half rails onthe head sides of the latter and provided With the median rib 11', whichdefines the reinforcing collar Yon that side of the Weld. Formed on orsecured to the underv facev of the headboard 5 isA a pattern section12', which defines the other half or section of the vslag lbasin orreaction chamber in the .top `ofthe finished mold, which patternsection" includes a projectionl, whichdeiines the which connects themold cavity withthe bottom of the slag basin,

vent or riser openingin thefini'shed moldr and Asthus constituted, eachhalf pattern, or the pattern for each half moldsectiomcom- Y prises apattern" section Von the lrbpackboard,

Secured to the under` face of the headboard When the pattern sets aretogether by the latches 6 and 6', lthe pattern,y as'a wholefissubstantially like the standard' pattern for forming one-halfof a`two-partk Ymold and may v-be employed in the usual manner for formingrsuch mold half.l Under Y theseconditions, the patterns for therespective mold halves are practically identical with the standardpatterns used in the same'relation. The twoY parts of each mold box halfsectiony are locked together and placed in' proper position on therespective baokboards andthe refractory material rammed into themold boxsectionsin the "customary man-5 ner, completely fillingthe space in"`said vbox sections about the patterns. YWhen' the ramming operation iscomplete, theheadboarlds 5 andl 5 are vunhooled fromy thecorrespondingbackboards and moved relatively to thelatter tothe positions indicatedin dottedv lines soY inV Fig. 1, thereby completely withdrawing thelpattern elements carried by the headboards from the mold and permittingthe half moldsections to be withdrawnfrom the pattern elements carriedby thebackboards. It

will'be understood, of course, that, Vin this particular operation, thegroove inl the pattern, corresponding to the grooves in the rail ends,is provided with yafiller or is covered v yby a thin strip ofmetal, asis usual in the Y formation ofa standard two part mold, after which theVsupplementalpart of the mold to fill'zthe groovesis formed 'separatelyin the grooves of the ad] acent railv sectionsbe'fore theftwo part .moldis applied.Y l y to be employed in forminga four part mold for usewithout interrupting traffic, the vtvvo sections of each mold'bofx halfrare separated by thin shims or partingplates 15, 15 and then applied tothe I Vvbackboardsfas before, so that, when the `refractory material hasbeen rammed into .the

mold box sections and theheadboards with-2 drawn, the upperl section ofthe moldbox halfl on the groove side may be Withdrawn by first movingthe same along the backboardtofree the refractory portionV of the moldoccupying the grooves andthen lifting the moldsection off thebackboard.As therev are noreentrant angular sections on the pattern on the headside, the two sections of the half mold on the backboard 1 may be liftedoff directly, after which the two sections of each half mold box may belockedtogether and are ready for- Y application to the rail ends toeffect the for.

mation of the joint thereat, the -four sections of the completed mold asapplied to girder or cope, and means for trilby rails occupying therelation indicated in Fig. 4.

In applying the invention to molds for forming the four sectionsnecessary to enclose the ends of ordinary T-rails, the only changesinvolved will be in the particular shapes of the patterns applied to thebaseboards and the headboards, respectively, the patterns taking theshapes of the spaces indicated in Fig. 5, that is to say, the spacesdefining the mold cavity proper, the slag basin, the pouring gate andthe vent or riser. v l

It will be understood that in the construction of the four part mold tobe applied to either type of rails, the two upper portions of each halfmold section, as indicated at a, a, in Figs. 4 and 5, are clampedtogether and, when so united, constitute a separable cope, which may beremoved and replaced at will on the lower mold sections b, b, toaccommodate traflic without interrupting-the operations incidental tothe formation of the (weld.

What I claim is: p

l. Pattern sets for rail welding molds, comprising baclrboards havingpattern sections defining the mold cavity proper thereon, f headboardsnormal to the planes of the respective backboardsand having patternsections thereon defining the cavities in the connecting thecorresponding backboards and headboards to permit movement of eachheadboard in a direction parallel to the plane ofthe correspondingbaclboard and normal to its own plane.

2. Pattern sets for rail welding molds, comprising backboards havingpattern sections defining the mold cavity proper thereon, headboardsnormal-to the planes of the respective backboards and having patternsections thereon defining the cavities inthe cope and slidingconnections between the corresponding backboards and headboards topermit movement of each headboard 'in a direction parallel to the planeofthe vcorresponding backboard and normal to its own plane.

3. Mating pattern sets for rail welding molds, each comprising abackboard having a pattern section thereon defining one-half of the moldcavity, and a headboard slidably connected to the backboard for movementin a direction longitudinally of and parallel to the face of saidbackboard and having a pattern section on its inner face defining aportion of the cope section cavity. p

4. Mating pattern sets forvrail welding molds, comprising 'backboardsand headboards having pattern sections thereon adapted to defineportions of the mold cavity and a cope cavity respectively, and meansfor adjustably connecting the headboards and the respective backboards;whereby each backboard pattern section may be stripped from the moldafter movement of the headi yboards board relatively to the backboard tostrip the whereby each 6. A pattern set for one-half of a railV iwelding mold, comprising a backboard havlng a of the body cavity of themold, longitudinal guides on the rear of the backboard, a headboardsubstantially normal to the face of the backboard, a slide secured tothe'headboard pattern section thereon defining a part and engaging saidguides forfmovement along said lbackboard, and a pattern section on theinner face of said headboard defining a part of the cope cavity;L

In testimony whereof I affix my signature.y

BELA RONAY.

